(Reaffirmed 2002) IS : 11452- 1985 Indian Standard METHOD OF TESTING AIR-SETTING REFRACTORY MORTARS Refractories Chairman SHRI I. C. Mom Sectional Committee, SMDC 18 Representing Steel Authority of India Plant ), Rourkela Ltd ( Rourkrla Steel SH~I R. K. SAFGIU ( Alterzzate to Shri I. C. Modi ) Industrial Research SKRI P. S. V. ANANTHANAI~ATANA Engineering & Mineral -Labora 4 4 Refractoriness, Drying 4.2 For testing all parameters for two component mortar systems, the test sample should be prepared by mixing thoroughly the powder component and the recommended proportionate quantity of liquid before taking up the testing except sieve analysis. In the case of a single component premixed mortars the sample may be taken directly. 5. SIEVE ANALYSIS 5.1 The sieve analysis shall be conducted in accordance with IS : 1528 ( Part 14 )-1974* on the dry powder component in the case of two component mortar and on ready mixed material in case of a single component material, immediately after sampling so that setting does not take place. -.._ and physical test for refractory materials: Part 14 Sieve *Methods of sampling analysis ( jirst revision ) . 4 IS:11452 6. CHEMICAL ANALYSIS analysis shall be carried out in accordance - 1985 6.1 The chemical IS : 1527-1972*. 7. BOND with STRENGTH 7.1 Principle -- This method of test covers a procedure for determining the bond strength of all types of air-setting refractory mortars by conducting the modulus of rupture test of oven dried bricks joined with .the test mortar. 7.2 Apparatus a) Two The following apparatus will be used: spacing oven, rods of 3 mm dia each, and testing machine with modulus of rupture rig. b) Drying c) Compression 7.3 Sampling - Representative samples shall be drawn from the containers or bags. The contents shall be thoroughly mixed in the container or transferred without loss to a clean impervious receptacle of larger size and mixed thoroughly to a uniform consistency. In the case of two component mortar systems requisite quantity of liquid shall be added and mixed thoroughly as above. 7.4 Procedure - Select 5 standard bricks of size 230 X 113 X 75 mm having a modulus of rupture value higher than that anticipated in the mortar. Cut each of the five bricks into two equal parts on a plane parallel to the 75 x 113 mm face. Use the uncut 75 x 113 mm face of each half brick to form the mortar joint. Apply the mortar to the uncut face to 5-6 mm thickness and squeeze to form a joint of 3 mm in thickness of the uncut and horizontally placed face of one half brick. This is facilitated by placing two spacer-rods in the mortar parallel to the 75 mm edges of the brick ( see Fig. 1 ). Place the uncut face of the other half brick on the mortar. Force out the excess mortar in the joint by pressing on the top half brick and at the same time moving it with a to and fro motion in the direction of 113 mm dimension of the brick using the spacer rods as rollers. Withdraw the rods and clean the excess mortar from the surface of the joint. Allow the joints to air dry undisturbed at room temperature for 24 hours and then oven dry at 110°C for at least 12 hours. Upon removal from the oven allow them to cool and test them for modulus of rupture ( see Fig. 2 and 3 ). The modulus of rupture test should be conducted on a span of 180 mm as given in IS : 1528 ( Part 5 )-19747. Report the individual values of the three determinations for the modulus of rupture of the mortar joint as the bond strength. __~___ *Methods of chemical analysis of high silica refractory materials (first revision ). TMethods of sampling and physical tests for refractory materials: Part 5 Determination of modulus of rupture ( f;rsr r&ion ). 5 IS:11452-1985 #3ROD t 115 t' / CUT EDGE All dimensions in millimetres. FIG. 1 PREPARATION OF TEST PIECE FOR MODULUSOF RUPTURE TEST, f All dimensions in millimetres. FIG. 2 ARRANGEMENT FOR MODULUSOF RUPTURE TEST $6 IS :11452 -1985 7 PLATEN OF TESTING MACHINE 3mm MORTAR All dimensions in millimetres. FIG. 3 ALTERNATE DESIGN OF BEARING EDGES FOR MODULUS OF RUPTURE TEST 8. REFRACTORINESS 8.1 Refractoriness shall be in IS : 1528 ( Part 1 )-1980t. 9. DRYING 9.1 Apparatus 9.1.1 Kiln - The kiln used for the test shall be of such design as not to permit the flame to impinge directly from the burner upon the test The kiln atmosphere during the test shall be kept as oxidizspecimen. If it is not possible to use the kiln, an electric ing as is practicable. furnace may be used maintaining the conditions stated above for the kiln. *Methods of sampling and physical test for refractory materials: Part 1 Determination of pyrometric cone equivalent ( PCE ) or softening point ( second ~enision). determined according to method laid down AND FIRING SHRINKAGE TEST 7 IS : 11452 - 1985 9.1.2 Thermocouples and Pyrometers - For temperatures up to 145O"C, a platinum/platinum rhodium thermocouple and pyrometer of the recording type shall be provided. For temperatures above 1 450% an optical pyrometer shall be used. 9.2 Preparation of Test Specimen - Three test specimens of the size 50 x 50 x 125 mm may be formed in metal moulds. The ready mix mortar or two-component mortar system shall be made to the working consistency and poured in the mould. This shall be allowed to set undisturbed at the room temperature for 24 hours. After the mortar has set ( there being no further deformation ), two marks 75 mm apart uni-formly spaced front the centre of the specimen, shall be made with the help of vernier callipers on each specimen. The samples shall then be dried for 12 hours at 1lO"C. The distance between the two marked points shall be measured with the help of the vernier calipers and percentage drying shrinkage shall be calculated for each specimen. To ensure that the specimens have dried completely, these shall be again dried at 110°C for 12 hours and shrinkage measured again as per the procedure outlined above. The average of the 3 readings for the specimens shall be the percentage drying shrinkage. 9.3 Firing Shrinkage - After the drying shrinkage measurement, the specimens shall be fired up to the intended service temperatures in the test kiln ( furnace ). Location of the test specimens, temperature measurements, temperature schedule and cooling shall be in accordance with IS : 1528 ( Part 6 )-1974*. Percentage firing shririkage shal! then be determined for each specimen and the average of the 3 readings shall be the percentage firing shrinkage for the mortar. 9.3.1 Temperature and time duration of firing shall be as agreed t@ between the uber and the manufacturer depending on the requirements of the user. *Methods for sampling and physical tests for refractory nation of permanent change after reheating (first reuision ). materials: Part 6 Determi- 8 IS : 11452- 1985 ( Continued ,from page 2 ) Panel Concaner DR for Monolithic Refractories anti High Cement, SMDC! 18/P-7 RepTwtiq Alumina A. K. CH~TTERJEE Members The Associated Cement Companies Ltd, Bombay SHRI S. P. BaNr;RJI SHRI BRARAT BHASXAR SHRI RAJXEV BIIABI~ER ( Central C!ass & Ceramic Research Calcutta The Ishwar Industries Ltd, New Delhi Institute, Steel .riuthority of India Ltd ( Bokaro Steel Plant ), Bokaro SHRI H. G. UPAL)H~-AP ( Alternate ) Belpahar Refractories Ltd, Bclpahar SHRI T. K. GH~SE SHRI P. BH.~TTA(,IIAIZYA ( dlternate ) of India Ltd ( Rourkela Steel SHRI K. KISHTIA Steel Authorty Plant ), Rourkela SHRI SRIRAN ( Alternate) SIIRI u. v. s. POROV Refractory Specialities ( India ) Ltd, New Delhi SHRI J. SARIW ( Alternate) Orissa Cement Ltd, Rajgangpur SI~RI K. K. PRASAn Drt S. L. KOLH~\TPAR ( Alternate ) Engineers India Ltd, New Delhi DR T. V. PRASAD Cement Research Institute of India, New Delhi SHRI M. V. RANGA RAO SJrRI V. K. AROMA ( Ahrnate ) National Metallurgical Laboratory DR M. R. K. RAO ( CSIR ), Jamshedpur SHHT M. C. KUNDRA ( Alternate ) Bharat Heavy Electricals Ltd, Tiruchchirappalli Srrn~ R. SANI~AHAX SHRI C. S. R. ADHITHYAN ( Alternate ) Kumardhubi Fireclay & Silica Works Ltd, SRRI H. N. TRIPATHI Calcutta DR G. D. SINQH ( Altcrnate ) SHXI S. R. BISWAS SHRI 13. V. B. Par ( Aknnte SERI B. K. P. CHJ~BI~~\R Alternate ) ) The Associated Cement Companies Ltd, Bombay